Fluorocarbon resin composite, cookware, cooker, roller for office automation equipment, belt for office automation equipment , and method for producing them

ABSTRACT

A fluorocarbon resin composite includes a fluorocarbon resin layer on a base, in which a fluorocarbon resin constituting the fluorocarbon resin layer is crosslinked by electron beam irradiation, and the base has a desired shape obtained by machining. The fluorocarbon resin is composed of a tetrafluoroethylene-perfluoro(alkyl vinyl ether) copolymer, polytetrafluoroethylene, or a mixture of the tetrafluoroethylene-perfluoro(alkyl vinyl ether) copolymer and polytetrafluoroethylene. A fluorocarbon resin composite, cookware, and a roller and a belt for use in office automation equipment are each produced by applying an uncrosslinked fluorocarbon resin on a base, subjecting the fluorocarbon resin to electron beam irradiation in a low-oxygen atmosphere to crosslink the fluorocarbon resin while the temperature of the fluorocarbon resin is maintained at a temperature equal to or higher than the melting point of the fluorocarbon resin, and machining the base into a desired shape. There is also provided methods for producing them.

TECHNICAL FIELD

The present invention relates to a fluorocarbon resin composite,cookware and cookers including the fluorocarbon resin composite, rollersincluding the fluorocarbon resin composite, for example, fixing rollers,transfer rollers, pressing rollers, charging rollers, and developingrollers, for use in office automation equipment such as copiers, beltsincluding the fluorocarbon resin composite, for example, fixing belts,belts used for fixing sections, transfer belts, and transfer fixingbelts, for use in office automation equipment, and methods for producingthem.

BACKGROUND ART

Fluorocarbon resins such as polytetrafluoroethylene (PTFE) haveexcellent nonadhesiveness, heat resistance, and chemical resistance andthus are often used as materials constituting coatings of cookers suchas rice cookers and cookware such as hot plates and frying pans andtopcoat layers of fixing rollers for use in office automation equipmentsuch as copiers. The reason fluorocarbon resins such as PTFE haveexcellent heat resistance and chemical resistance is that in astructural formula described below, the bonding strength between C and Fis the highest among organic substances (116 kcal/mol) and that fluorineatoms (F) entirely cover carbon chains to protect the C—C bonds. Thereason for the excellent nonadhesiveness is a very low polarization ofcharges because of the symmetry of the atomic arrangement in a molecule,a low cohesive force between molecules, and a significantly low surfaceenergy.

Fluorocarbon resins have these excellent physical properties butdisadvantageously have poor abrasion resistance. The reason for this isthat molecules are readily detached because of a low surface energy anda low cohesive force between fluorine atoms (F—F).

To overcome this problem, currently commercially available fluorocarbonresins compensate the weakness by forming very long molecular chainshaving a degree of polymerization of about 10,000 to several hundredthousands, i.e., a molecular weight of about a million to tens ofmillions, to increase the bonding strength between fluorocarbon resins.However, it is difficult to achieve a higher molecular weight because ofproblems with formability and so forth (a reduction in flowability).Thus, sufficient properties are not provided. Furthermore, the adhesionof fluorocarbon resins to bases is a processing problem due to excellentnonadhesiveness. To solve this problem, in the case of using a basecomposed of a metal such as aluminum, it is necessary to conduct anadditional step of performing etching treatment to form irregularitiesor forming an adhesive layer such as a primer.

In recent years, a technique in which a fluorocarbon resin, which is arepresentative of polymers degraded by electron beams, is crosslinked byelectron beam irradiation at a temperature equal to or higher than themelting point thereof in an oxygen-free atmosphere has been developed(Patent Documents 1 and 2). It is found that to solve the problem inwhich the molecules are readily detached because of a low cohesive forcebetween fluorine atoms (F—F), crosslinking a fluorocarbon resin resultsin a three-dimensional network structure of fluorine atoms as shown in astructural formula below, so that the polymeric chains are stronglybonded to each other, significantly improving the abrasion resistance.

-   [Patent Document 1]Japanese Patent No. 3587071-   [Patent Document 2]Japanese Patent No. 3587072

DISCLOSURE OF INVENTION Problems to be Solved by the Invention

However, in the technique described in each of Patent Documents 1 and 2,crosslinking is performed by electron beam irradiation of a fluorocarbonresin powder while the fluorocarbon resin powder is floating, thusfailing to provide a fluorocarbon resin having a small particle sizesuitable for the formation of a fluorocarbon resin dispersion (adispersion of a fluorocarbon resin having a particle size on the orderof submicrons dispersed in water). If pulverization is performed, it isusually difficult to form a fluorocarbon resin having a particle size onthe order of submicrons. Thus, the resulting fluorocarbon resin is notsuitably used as a material for a dispersion commonly used for a thinfilm of a fluorocarbon resin. Accordingly, it is difficult to form athin fluorocarbon resin layer (coating film) suitable for cookware usinga fluorocarbon resin dispersion containing a fluorocarbon resin producedby this technique. Furthermore, it is difficult to form a topcoat filmof a fixing roller and surface layers of a transfer belt and a transferfixing belt.

For example, the fixing roller is used to fix toner transferred torecording paper. The transfer belt is used to transfer toner torecording paper. Thus, a fluorocarbon resin is preferably used as amaterial constituting a topcoat film of the fixing roller and a surfacelayer of the transfer belt because of its excellent toner releasability.

Meanwhile, a fluorocarbon resin layer disadvantageously has low abrasionresistance as described above. Thus, in the case where toner-fixingtreatment and toner-transfer treatment for hundreds of thousands ofrecording sheets are performed using the fixing roller and the transferbelt, the fluorocarbon resin layer is worn by friction between therecording sheets and the fixing roller and between the recording sheetsand the transfer belt, thereby causing problems such as a reduction insurface roughness (clogging of toner and so forth reduces tonerreleasability). Alternatively, a problem is caused in which thefluorocarbon resin layer is detached at portions that come into contactwith both edges of each of the recording sheets. It is thus necessary toadequately ensure the thickness of the fluorocarbon resin layer, leadingto difficulty in reducing the thickness of the topcoat film of thefixing roller or the surface layer of the transfer belt.

Furthermore, in the case of the fixing roller and the transfer fixingbelt each having the function of fixing toner transferred to a recordingsheet, they are used while being heated by a heater arranged insidethereof. In the case of a high-speed copier, a large number of recordingsheets takes heat from the fixing roller and the transfer fixing belt;hence, the temperatures of the fixing roller and the transfer fixingbelt tend to be reduced. Accordingly, in order not to reduce thetemperatures of the fixing roller and the transfer fixing belt, it isnecessary to reduce the thicknesses of the fixing roller and thetransfer fixing belt for efficient conduction of heat from the heater.Alternatively, it is necessary to increase the heating temperature ofthe heater.

To solve the above-described problems with the fixing roller, thetransfer belt, and the transfer fixing belt, it is conceivable that theaddition of a filler such as a fine glass powder to a fluorocarbon resinwill improve the abrasion resistance, leading to a reduction in thethickness of the fluorocarbon resin layer. However, this raises newproblems in which the nonadhesiveness and the surface roughness aresignificantly reduced.

Meanwhile, an increase in the heating temperature of the heaterdisadvantageously causes the deterioration of rubber constituting anelastic layer and a further reduction in abrasion resistance due to thethermal degradation of the fluorocarbon resin layer. To impartelasticity to the belt, a soft intermediate layer composed of siliconeor the like is provided. However, an increase in the thickness of thesurface layer of the fluorocarbon resin reduces the flexibility of theentire belt.

Accordingly, it is a first object of the present invention to provide afluorocarbon resin composite including a fluorocarbon resin layer havingimproved abrasion resistance while nonadhesiveness, which is a featureof a fluorocarbon resin, is maintained, cookware, a cooker, and methodsfor producing them.

It is a second object to provide a roller or belt for use in officeautomation equipment, the roller or belt including a fluorocarbon resinlayer having improved abrasion resistance and heat resistance whilenonadhesiveness, which is a feature of a fluorocarbon resin, ismaintained, and a method for producing the roller or belt.

Means for Solving the Problems

The inventors have conducted intensive studies and have found that theforegoing problems are easily solved by a devised method for forming afluorocarbon resin layer. This finding has led to the completion of thepresent invention.

Furthermore, the inventors have conducted intensive studies and havealso found that after the application of a fluorocarbon resin, anelectron beam is allowed to reach a base or intermediate layer(hereinafter, collectively referred to also as a “base and so forth”),thereby significantly improving the adhesion of the fluorocarbon resinto the base and so forth simultaneously with improvement in abrasionresistance.

Inventions of claims 1 to 7 described below are defined as an aspectcommon to a first aspect and a second aspect of the present invention.Inventions of claims 8 to 10 are defined as the first aspect of thepresent invention. Inventions of claims 11 to 21 are defined as thesecond aspect of the present invention. The first aspect and the secondaspect are aspects that achieve the first object and the second object,respectively.

The inventions of the claims will be described below.

According to an invention described in claim 1,

a fluorocarbon resin composite includes a fluorocarbon resin layer on abase, in which a fluorocarbon resin constituting the fluorocarbon resinlayer is crosslinked by electron beam irradiation, and the base has adesired shape obtained by machining.

In the invention of this claim, since the fluorocarbon resin iscrosslinked, it is possible to improve the abrasion resistance of thefluorocarbon resin layer while maintaining the nonadhesiveness of thefluorocarbon resin layer.

In a conventional technique for crosslinking a fluorocarbon resin byelectron beam irradiation, only a fluorocarbon resin having a largeparticle size is obtained. It is thus difficult to form a thinfluorocarbon resin layer suitable for cookware. That is, the thinfluorocarbon resin layer is preferably formed as follows: A dispersionof fluorine particles having a particle size of 0.1 μm to severalmicrometers dispersed in water is used. The dispersion is applied to atarget surface by, for example, a spin coating method, a dipping method,or a spraying method, dried, and baked (the particles are melted to forma fluorocarbon film). However, a large particle size of the fluorocarbonresin causes the precipitation of particles in the dispersion and theclogging of a nozzle, leading to difficulty in performing coating. Evenif coating can be performed, it is difficult to obtain a smooth surfacebecause the surface state depends on the size of the fluorocarbonparticles.

In contrast, according to the invention of this claim, for example, afluorocarbon resin layer is formed on a substantially flat base using adispersion of usual uncrosslinked fluorocarbon particles having a smallparticle size. Thus, it is possible to easily form a thin fluorocarbonresin layer suitable for cookware.

Conventionally, according to a common method for forming a fluorocarbonresin layer in the production of cookware, it is difficult to subjectthe entire fluorocarbon resin layer to electron beam irradiation.

That is, as a method for forming a coating film for use in cookware, amethod is generally employed in which after a base is pressed into apredetermined shape, the fluorocarbon resin is applied by, for example,spraying and then baked (hereinafter, a method in which a fluorocarbonresin is applied after machining is referred to as an “after-coatmethod”). In the case where cookware produced by the after-coat methodis subjected to electron beam irradiation to crosslink the fluorocarbonresin in order to improve abrasion resistance, for example, it isdifficult to simultaneously subject a fluorocarbon resin layer arrangedon a horizontal inner wall of a bottom and a substantially verticalinner surface of a side wall of a rice cooker or a frying pan toelectron beam irradiation.

That is, for the fluorocarbon resin layer located at a surfaceperpendicular to the direction of electron beam irradiation, the entirefluorocarbon resin can be subjected to electron beam irradiation becausethe thickness direction corresponds to the transmission direction ofelectron beams. However, for the fluorocarbon resin layer located at asubstantially vertical surface obtained by machining, i.e., a surfaceparallel to the direction of electron beam irradiation, only part of thefluorocarbon resin (portion facing an electron beam irradiationapparatus) is subjected to electron beam irradiation because thethickness direction does not correspond to the transmission direction ofelectron beams.

In contrast, according to the invention of this claim, after theformation of the fluorocarbon resin layer on the base, electron beamirradiation is performed before the base is machined (in this way, amethod of applying the fluorocarbon resin before machining is referredto as a “precoat method”).

As described above, since the base is substantially flat, the entiresurface of the fluorocarbon resin layer can be located at a positionperpendicular to the irradiation direction of electron beams. That is,it is possible to subject the entire fluorocarbon resin layer toelectron beam irradiation because the thickness direction of the entirefluorocarbon resin layer corresponds to the transmission direction ofelectron beams, thereby resulting in cookware including the fluorocarbonresin layer having excellent abrasion resistance.

Furthermore, it is possible to efficiently produce cookware becausecrosslinking is rapidly performed by electron beam irradiation, which isa simple method. Note that a metal base is mainly used as the base.

According to an invention described in claim 2,

in the fluorocarbon resin composite according to Claim 1, thefluorocarbon resin is composed of one selected from atetrafluoroethylene-perfluoro(alkyl vinyl ether) copolymer (PFA),polytetrafluoroethylene (PTFE), and a fluorinated ethylene-propylenecopolymer (FEP), or a mixture of two or three compounds selected fromPFA, PTFE, and FEP.

In the invention of this claim, the fluorocarbon resin is composed ofone selected from the tetrafluoroethylene-perfluoro(alkyl vinyl ether)copolymer (PFA), polytetrafluoroethylene (PTFE), and the fluorinatedethylene-propylene copolymer (FEP), or a mixture of two or threecompounds selected from these compounds. Thus, a thin film of thefluorocarbon resin having excellent heat resistance and resistance tostress cracking is obtained.

According to an invention described in claim 3,

in the fluorocarbon resin composite according to Claim 1 or 2, anelectron beam during the electron beam irradiation reaches the basethrough the fluorocarbon resin layer.

Like the invention of this claim, the crosslinking of the uncrosslinkedfluorocarbon resin on the base by electron beam irradiation in which anelectron beam reaches the base through the fluorocarbon resin layersignificantly improves the adhesive strength between the base and thefluorocarbon resin layer compared with the case where an electron beamdoes not reach the base. The reason for the improvement in the adhesionto the base is probably as follows: Electron beam irradiation causescleavage of a main chain or a side chain. In particular, when thetemperature of the fluorocarbon resin is heated to a temperature equalto or higher than its melting point, active radicals are generated. Theresulting radicals are bonded to the base because there is no substance,such as oxygen, which is readily bonded to the radicals. For example,the electron beam is allowed to reach the base by adjusting anacceleration voltage during electron beam irradiation in response to thethickness of the fluorocarbon resin layer.

According to an invention described in claim 4, in the fluorocarbonresin composite according to any one of Claims 1 to 3, the fluorocarbonresin layer has a thickness of 70 μm or less.

For example, in a rice cooker, a frying pan, a pot, or the like,generally, the fluorocarbon resin layer needs to have a thickness ofabout 70 to 120 μm. However, an increase in the thickness of thefluorocarbon resin layer can form a crack on baking the fluorocarbonresin layer. Frequently, multiple applications of the fluorocarbon resinresult in a multilayer coating. This leads to increases in machiningcost and the cost of materials.

According to the invention of this claim, crosslinking by electron beamirradiation improves the abrasion resistance of the fluorocarbon resinlayer, so that the thickness of the fluorocarbon resin layer can bereduced to 70 μm or less while the abrasion resistance is maintained. Asa result, the machining cost and the cost of materials can be reduced byproviding a single-layer coating or a reduction in the number of layersof a multilayer coating. From the viewpoint of thermal conductivity andproductivity, the fluorocarbon resin layer preferably has a thickness of30 μm or less and more preferably 10 μm or less. In such a thin film,the abrasion resistance is ensured.

The distance in which an electron beam transmits the fluorocarbon resinlayer is determined by the acceleration voltage of the electron beam andthe specific gravity of the fluorocarbon resin. The specific gravity isintrinsic to the fluorocarbon resin. When the thickness of thefluorocarbon resin layer to be subjected to crosslinking treatment isdetermined, an acceleration voltage needed is determined. The distancein which an electron beam transmits the fluorocarbon resin is increasedwith increasing acceleration voltage. That is, an increase in thethickness of the fluorocarbon resin layer increases the accelerationvoltage required to crosslink the entire fluorocarbon resin layer, sothat it is necessary to use a large-sized expensive electron beamirradiation apparatus.

According to the invention of this claim, crosslinking by electron beamirradiation improves the abrasion resistance of the fluorocarbon resinlayer. The thickness of the fluorocarbon resin layer can be reduced to70 μm or less, preferably 30 μm or less, and more preferably 10 μm orless while the abrasion resistance is maintained. It is thus possible toperform crosslinking with an ultrasmall, inexpensive general-purposeelectron beam irradiation apparatus with an acceleration voltage of 60kV.

According to an invention described in claim 5,

in the fluorocarbon resin composite according to any one of Claims 1 to4, the amount of the electron beam irradiation is in the range of 1 kGyto 500 kGy.

In the invention of this claim, the amount of the electron beamirradiation is in the range of 1 kGy to 500 kGy, thereby assuredlycrosslinking the fluorocarbon resin and suppressing cleavage ofpolymeric chains of the fluorocarbon resin due to excessive irradiation.

An amount of the electron beam irradiation of 50 kGy or more results inan increase in crosslink density, improving the abrasion resistance. Anamount of the electron beam irradiation of 300 kGy or less provides theflexibility of the film, suppressing the occurrence of cracking duringprocessing such as pressing. An amount of the electron beam irradiationexceeding 300 kGy causes degradation of the polymer, reducing theabrasion resistance. Thus, the amount of the electron beam irradiationis preferably in the range of 50 kGy to 300 kGy.

According to an invention described in claim 6,

in the fluorocarbon resin composite according to any one of Claims 1 to5, the base is composed of aluminum, an aluminum alloy, or stainlesssteel.

In the invention of this claim, the base is composed of aluminum, analuminum alloy, or stainless steel. In this case, the base is easilysubjected to machining such as pressing and spinning and serves as amaterial for a lightweight cookware.

According to an invention described in claim 7,

in the fluorocarbon resin composite according to Claim 6, thefluorocarbon resin layer is formed on the non-surface-treated base, andin a cross-cut test (JIS-K-5400, 1998 edition), the fluorocarbon resinlayer is not detached after 100 repetitions of a peeling operation usingan adhesive tape.

In the invention of this claim, the fluorocarbon resin layer having astrong adhesion to the base is obtained without performing surfacetreatment of the base. It is thus possible to provide the fluorocarbonresin composite that is easily produced.

Note that “not detached” described above indicates that the fluorocarbonresin composite is classified into class 10 specified by JIS-K-5400(1998 edition).

According to an invention described in claim 8,

cookware includes the fluorocarbon resin composite according to any oneof Claims 1 to 7.

Fluorocarbon resins have excellent nonadhesiveness and the advantagethat food does not easily adhere to a rice cooker, a frying pan, or thelike. Disadvantageously, the adhesion strength between the fluorocarbonresin and the base is low. To solve the problem, a technique for etchinga surface of a base (Japanese Patent No. 1239856) and the use of aprimer layer (adhesive layer) are reported. However, they are notsufficient, causing an increase in cost.

In contrast, the cookware according to the invention of this claim iscomposed of the fluorocarbon resin composite. Unlike conventionalcookware, the cookware has excellent adhesive strength between the baseand the fluorocarbon resin layer and leads to low cost.

According to an invention described in claim 9, a cooker includes thecookware according to Claim 8.

In the invention of this claim, the cooker advantageously has excellentproperties described in claim 8.

According to an invention described in claim 10,

a method for producing a fluorocarbon resin composite includes the stepsof applying an uncrosslinked fluorocarbon resin onto a base, heating thefluorocarbon resin to a temperature equal to or higher than the meltingpoint of the fluorocarbon resin, subjecting the fluorocarbon resin toelectron beam irradiation in a low-oxygen atmosphere to crosslink thefluorocarbon resin, and machining the base in such a manner that thebase has a desired shape.

In the invention of this claim, after the uncrosslinked fluorocarbonresin is applied onto a base, the fluorocarbon resin is heated to atemperature equal to or higher than the melting point of thefluorocarbon resin, and then the fluorocarbon resin is subjected toelectron beam irradiation in a low-oxygen atmosphere to crosslink thefluorocarbon resin. Thus, the thin crosslinked fluorocarbon resin filmon the base, which has been difficult to form in the past, is easilyformed. The uncrosslinked fluorocarbon resin can be used as a powderhaving a small particle size. Thus, the resin can be used as a rawmaterial for a fluorocarbon resin dispersion. Since a crosslinkedfluorocarbon resin having a large particle size is not used, a thin filmcan be formed.

For example, a fluorocarbon resin dispersion (a dispersion of theuncrosslinked fluorocarbon resin dispersed in water) is applied by spincoating to a surface of the plate-like base to form a thin film of thefluorocarbon resin. Spin coating is a method as described below. Thefluorocarbon resin dispersion is dropped on the middle portion of thebase while the base is being rotated. The dispersion is spread by acentrifugal force, so that the thin fluorocarbon resin film having auniform thickness is formed on the surface of the base. Next, thefluorocarbon resin is baked by heating. The resulting fluorocarbon resinis heated to a temperature equal to or higher than its melting point.The fluorocarbon resin is crosslinked by electron beam irradiation in alow-oxygen atmosphere. After cooling the base and the fluorocarbonresin, the base is machined into a desired shape. Machining indicatesthat an inner pot of a rice cooker or a frying pan is formed by pressingor spinning. In this way, it is possible to easily produce cookwarehaving improved abrasion resistance and adhesive strength whilenonadhesiveness, which is a feature of a fluorocarbon resin, ismaintained. To increase the crosslink density, the oxygen concentrationin the low-oxygen atmosphere is preferably set 1000 ppm or less and morepreferably 500 ppm or less. Furthermore, an excessively small oxygenconcentration is not preferred. Specifically, a nitrogen gas atmospherecan be preferably used.

According to an invention described in claim 11,

a roller or a belt for use in office automation equipment includes afluorocarbon resin layer on a circular base, in which the fluorocarbonresin layer is crosslinked by electron beam irradiation.

In the invention of this claim, the fluorocarbon resin is crosslinked byelectron beam irradiation. The abrasion resistance of the fluorocarbonresin layer is improved while the nonadhesiveness of the fluorocarbonresin is maintained, reducing the thickness of the fluorocarbon resinlayer. Thus, in the fixing roller or a transfer fixing belt, heat from aheater arranged inside thereof is efficiently conducted. In the casewhere the fluorocarbon resin layer has a thickness of, for example, 10μm, 40% of heat from the heater arranged in the fixing roller or thetransfer fixing belt is lost. However, in the case where the thicknessis 5 μm, only 20% of heat is lost. It is thus possible to improve aprint speed without increasing the heating temperature of the heater.

An increase in the temperature of the heater causes thermal degradation,reducing the abrasion resistance. However, in the invention of thisclaim, the fluorocarbon resin is crosslinked by electron beamirradiation, thus improving the abrasion resistance of the fluorocarbonresin layer because the crosslinking of the fluorocarbon resineliminates the melting point, i.e., the fluorocarbon resin is not melt.Furthermore, in the present invention, the base is bonded to thefluorocarbon resin by electron beam irradiation, thus eliminating anadhesive layer (primer); hence, it is possible to significantly increasethe thermal conductivity of a roller or a belt for use in officeautomation equipment.

The foregoing technique can be applied to another roller or belt for usein office automation equipment. Examples of the roller for use in officeautomation equipment include a fixing roller, a transfer roller, apressing roller, a charging roller, and developing roller. Examples ofthe belt for use in office automation equipment include a transfer belt,a transfer fixing belt, and a belt used for a fixing section like thefixing belt.

According to an invention described in claim 12,

in the roller or the belt for use in office automation equipmentaccording to Claim 11, the fluorocarbon resin layer is composed of oneselected from a tetrafluoroethylene-perfluoro(alkyl vinyl ether)copolymer (PFA), polytetrafluoroethylene (PTFE), and a fluorinatedethylene-propylene copolymer (FEP), or a mixture of two or threecompounds selected from PFA, PTFE, and FEP.

In the invention of this claim, the fluorocarbon resin is composed ofone selected from PFA, PTFE, and FEP, or a mixture of two or threecompounds selected from these compounds. Thus, a thin film of thefluorocarbon resin having excellent heat resistance and resistance tostress cracking is obtained.

According to an invention described in claim 13,

in the roller or the belt for use in office automation equipmentaccording to Claim 11 or 12, an electron beam during the electron beamirradiation reaches the circular base through the fluorocarbon resinlayer.

As described above, the crosslinking of the uncrosslinked fluorocarbonresin on the base by electron beam irradiation in which an electron beamreaches the base through the fluorocarbon resin layer significantlyimproves the adhesive strength between the base and the fluorocarbonresin layer compared with the case where an electron beam does not reachthe base. According to the invention of this claim, it is thus possibleto provide the roller or the belt, for use in office automationequipment, in which the base and the fluorocarbon resin layer arestrongly bonded to each other.

According to an invention described in claim 14,

in the roller or the belt for use in office automation equipmentaccording to any one of Claims 11 to 13, the fluorocarbon resin layerhas a thickness of 20 μm or less.

In the invention of this claim, the abrasion resistance of thefluorocarbon resin layer is improved by crosslinking using electron beamirradiation. Thus, the thickness of the fluorocarbon resin layer can bereduced to 20 μm or less, preferably 10 μm or less, more preferably 3 μmor less for a roller, and 7 μm or less for a belt while the abrasionresistance is maintained. Thus, it is possible to increase the thermalconductivity of the roller or the transfer fixing belt. The temperatureof the heater need not be increased, thus suppressing the thermaldegradation of the fluorocarbon resin layer. Furthermore, it is possibleto reduce the machining cost and the cost of materials. Moreover, in thecase where the thickness is 20 μm or less, it is possible to performcrosslinking with an ultrasmall, inexpensive general-purpose electronbeam irradiation apparatus with an acceleration voltage of 60 kV.

According to an invention described in claim 15,

in the roller or the belt for use in office automation equipmentaccording to any one of Claims 11 to 14, the amount of the electron beamirradiation is in the range of 1 kGy to 500 kGy.

In the invention of this claim, the amount of the electron beamirradiation is in the range of 1 kGy to 500 kGy, thus assuredlycrosslinking the fluorocarbon resin.

According to an invention described in claim 16,

in the roller or the belt for use in office automation equipmentaccording to any one of Claims 11 to 15, the circular base is composedof a heat-resistant resin or a metal.

In the invention of this claim, the circular base is composed of aheat-resistant resin or a metal, thus providing the roller or the belt,for use in office automation equipment, having excellent heat resistanceand mechanical strength. Examples of the heat-resistant resin that canbe used include polyimide resins and polyamide-imide resins. Examples ofthe metal that can be used include stainless steel and aluminum.

According to an invention described in claim 17,

in the roller or the belt for use in office automation equipmentaccording to any one of Claims 11 to 16, the fluorocarbon resin layer isformed on the non-surface-treated base, and the fluorocarbon resin layerhas an adhesive strength of 0.5 Kg/1.5 cm or more in a peeling test.

In the invention of this claim, it is possible to achieve the adhesivestrength of the fluorocarbon resin layer to 0.5 Kg/1.5 cm or more andpreferably 0.8 Kg/1.5 cm or more by crosslinking using electron beamirradiation. As a result, the fluorocarbon resin layer having a strongadhesion to the base is provided without performing adhesive treatment,e.g., the use of a primer on a surface of the base.

According to an invention described in claim 18,

in the roller or the belt for use in office automation equipmentaccording to any one of Claims 11 to 17, an intermediate layer isarranged between the circular base and the fluorocarbon resin layer.

In the invention of this claim, the formation of the intermediate layerbetween the base and the fluorocarbon resin layer results in the rolleror the belt, for use in office automation equipment, capable ofcorresponding to requirement specifications of various users in additionto the effects described above. As the intermediate layer, for example,an elastic material such as silicone rubber is used.

According to an invention described in claim 19,

a method for producing a roller or a belt for use in office automationequipment includes the steps of applying an uncrosslinked fluorocarbonresin onto a circular base, heating the fluorocarbon resin to atemperature equal to or higher than the melting point of thefluorocarbon resin, and subjecting the fluorocarbon resin to electronbeam irradiation in a low-oxygen atmosphere to crosslink thefluorocarbon resin.

In the invention of this claim, after the application of theuncrosslinked fluorocarbon resin onto the base, the fluorocarbon resinis subjected to electron beam irradiation in a low-oxygen atmosphere tocrosslink the fluorocarbon resin while the temperature of thefluorocarbon resin is maintained at a temperature equal to or higherthan its melting point. Thus, the thin crosslinked fluorocarbon resinfilm on the base, which has been difficult to form in the past, iseasily formed.

The uncrosslinked fluorocarbon resin can be used as a powder having asmall particle size. Thus, a dispersion method or the like can beemployed. Since a crosslinked fluorocarbon resin having a large particlesize is not used, a thin film can be formed. As a result, the thermalconductivity can be improved while the nonadhesiveness, which is afeature of a fluorocarbon resin, is maintained. Furthermore, it ispossible to easily produce the roller or the belt, for use in officeautomation equipment, having improved abrasion resistance and heatresistance. As the low-oxygen atmosphere, a nitrogen gas atmosphere orthe like is preferred.

Moreover, after the formation of the uncrosslinked fluorocarbon resin onthe base, the resin is crosslinked by electron beam irradiation, thusleading to a significantly strong adhesion between the fluorocarbonresin and the base and eliminating the need for an adhesive layer(primer). The reason for the improvement in the adhesion to the base isprobably as follows: Electron beam irradiation causes cleavage of a mainchain or a side chain. Active radicals are generated because of a hightemperature. The resulting radicals are bonded to the base because thereis no substance, such as oxygen, which is readily bonded to theradicals.

According to an invention described in claim 20,

a method for producing a roller or a belt for use in office automationequipment includes the steps of placing a die (outlet) of an extruder ina low-oxygen atmosphere, extruding an uncrosslinked fluorocarbon resinfrom the die of the extruder onto the circular base, and subjecting thefluorocarbon resin to electron beam irradiation in the low-oxygenatmosphere to crosslink the fluorocarbon resin before the temperature ofthe fluorocarbon resin is decreased to a temperature equal to or lowerthan the melting point of the fluorocarbon resin.

In the invention of this claim, the thin film of the fluorocarbon resinis formed on the circular base by extrusion suitable for massproduction. Furthermore, electron beam irradiation is performed beforethe temperature of the molten fluorocarbon resin is decreased to atemperature equal to or lower than the melting point of the fluorocarbonresin. Thus, the roller or the belt for use in office automationequipment can be efficiently produced at low cost.

According to an invention described in claim 21,

the method for producing a roller or a belt for use in office automationequipment according to Claim 19 or 20 further includes after theuncrosslinked fluorocarbon resin is heated to a temperature equal to orhigher than the melting point of the fluorocarbon resin and thensubjected to electron beam irradiation in a low-oxygen atmosphere tocrosslink the fluorocarbon resin, performing rapid cooling before thetemperature of a layer located below the fluorocarbon resin reaches thedecomposition temperature of the layer.

As described above, the uncrosslinked fluorocarbon resin is heated to atemperature equal to or higher than its melting point and then subjectedto electron beam irradiation in a low-oxygen atmosphere, thereby easilyand assuredly crosslinking the fluorocarbon resin. The temperature ofthe layer located below the fluorocarbon resin is increased by heat fromthe fluorocarbon resin layer. However, rapid cooling is performed beforethe temperature reaches the decomposition temperature of the layer, sothat the properties of the lower layer are not reduced. Furthermore, ifthe fluorocarbon resin is rapidly cooled, the crystallization of thefluorocarbon resin does not easily occur, thus improving the flexresistance of the fluorocarbon resin layer.

That is, the uncrosslinked fluorocarbon resin is applied to an innerperipheral surface of a ring-shaped die (cylinder) by a thin-filmformation method such as a dispersion method. For example, siliconerubber is applied to the inner peripheral surface of the circularfluorocarbon resin layer to form the intermediate layer. Next, forexample, a polyimide resin serving as a base is applied to the innerperipheral surface of the intermediate layer to form a circular base.Then the circular base, the intermediate layer, and the fluorocarbonresin layer are pulled out from the die. The uncrosslinked fluorocarbonresin surface layer is heated to a temperature equal to or higher thanits melting point, subjected to electron beam irradiation in alow-oxygen atmosphere, and rapidly cooled before the temperature of theintermediate layer located below the fluorocarbon resin layer reachesthe decomposition temperature, thereby completing the belt for use inoffice automation equipment.

When the electron beam irradiation is performed, spiral irradiation ispreferred. A small electron beam irradiation apparatus is characterizedin that the amount of electron beam irradiation in the middle of anirradiation spot is large and the amount of electron beam irradiation inthe periphery is small. It is thus difficult to uniformly irradiate asurface of the fluorocarbon resin layer with electron beams by simpleelectron beam irradiation. Accordingly, the surface of the fluorocarbonresin layer is uniformly subjected to electron beam irradiation whilethe circular base provided with the fluorocarbon resin layer, which is atarget irradiated, on its outer peripheral surface is being rotated andwhile the electron beam irradiation apparatus arranged outside the baseis being translated in the axial direction of the circular base (thatis, spiral irradiation). Advantages

According to the first aspect of the present invention, the fluorocarbonresin layer on the base is crosslinked by electron beam irradiation andmachined into a desired shape. Thus, it is possible to provide thefluorocarbon resin composite, the cookware, or the cooker including thethin film of the fluorocarbon resin having excellent abrasion resistancewhile nonadhesiveness, which is a feature of a fluorocarbon resin, ismaintained.

According to the second aspect of the present invention, theuncrosslinked fluorocarbon resin is formed on the base, and thefluorocarbon resin is crosslinked by electron beam irradiation. Thus, itis possible to provide the roller or the belt, for use in officeautomation equipment, including the thin film of the fluorocarbon resinhaving excellent abrasion resistance and heat resistance whilenonadhesiveness, which is a feature of a fluorocarbon resin, ismaintained.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a graph showing the evaluation results of abrasion propertiesof fluorocarbon resin layers used in the present invention.

FIG. 2 is a graph showing the evaluation results of abrasion propertiesof fluorocarbon resin layers used in the present invention.

FIG. 3 is a conceptual cross-sectional view showing cookware accordingto an embodiment of the present invention.

FIG. 4 is a flow chart illustrating a procedure of producing cookwareaccording to an embodiment of the present invention.

FIG. 5 is a conceptual cross-sectional view showing a step according toan example of the present invention.

FIG. 6 is a conceptual drawing illustrating a method for irradiating afluorocarbon resin with electron beams.

FIG. 7 is a conceptual drawing illustrating a method for irradiating afluorocarbon resin layer with electron beams according to an example ofthe present invention.

FIG. 8 is a graph showing the evaluation results of abrasion propertiesof cookware according to an example of the present invention.

FIG. 9 is a plan view of cuts in a fluorocarbon resin layer of cookwareaccording to an example of the present invention, the cuts penetratingthorough the fluorocarbon resin layer.

FIG. 10 is a partially cutout conceptual drawing showing a roller foruse in office automation equipment according to an embodiment of thepresent invention.

FIG. 11 is a flow chart illustrating a procedure for producing a rollerfor use in office automation equipment according to an embodiment of thepresent invention.

FIG. 12 is a flow chart illustrating another procedure for producing aroller for use in office automation equipment according to an embodimentof the present invention.

FIG. 13 is a conceptual partially cross-sectional view illustrating aproduction process of a roller for use in office automation equipmentaccording to an embodiment of the present invention.

FIG. 14 is a conceptual partially cross-sectional view illustratinganother production process of a roller for use in office automationequipment according to an embodiment of the present invention.

FIG. 15 is a partially cutout conceptual drawing of a belt for use inoffice automation equipment according to an embodiment of the presentinvention.

FIG. 16 is a flow chart illustrating a procedure for producing a beltfor use in office automation equipment according to an embodiment of thepresent invention.

FIG. 17 is a flow chart illustrating another procedure for producing abelt for use in office automation equipment according to an embodimentof the present invention.

FIG. 18(A) is a conceptual front view and FIG. 18(B) is a conceptualside view, both views illustrating a method of electron beam irradiationin the production of a belt for use in office automation equipmentaccording to an embodiment of the present invention.

REFERENCE NUMERALS

-   -   1 base    -   2 fluorocarbon resin layer    -   3 stainless steel    -   20, 38, 53 electron beam irradiation apparatus    -   21 electron-beam tube    -   31 fluorocarbon resin composite    -   32 aluminum base    -   33 chamber    -   34 partition wall    -   35 hot plate    -   36 opening    -   37 titanium foil    -   38 cut penetrating to base    -   41, 71 circular base    -   51, 61 die (outlet) of extruder    -   52, 62 opening    -   63 hole    -   72 intermediate layer

BEST MODE FOR CARRYING OUT THE INVENTION

The present invention will be described below on the basis of the bestmode for carrying out the invention. The present invention is notlimited to embodiments described below. Various modifications can bemade to the following embodiments within the scope identical to thepresent invention and the scope of its equivalence.

1. Evaluation Example Fluorocarbon Resin and Production and Evaluationof Fluorocarbon Resin Composite Including Fluorocarbon Resin

i. Basic Abrasion Properties

To check the effect of a crosslinked fluorocarbon resin, a thinfluorocarbon resin film formed on a plate was crosslinked by electronbeam irradiation, and then adhesion and a change in abrasion propertieswere evaluated.

A sample was produced as follows: A fluorocarbon resin dispersion (PFAdispersion 950 HP, manufactured by Du Pont-Mitsui Fluorochemicals) wasapplied by dipping on a 5-mm-thick aluminum plate and baked at 380° C.to form a film with a thickness of 5 μm. An irradiation unit equippedwith a chamber and a hot plate (min-EB. output: 30 kV, manufactured byUshio Inc.) was prepared. The aluminum plate coated with thefluorocarbon resin was placed on the hot plate at a temperature of 400°C. under a nitrogen atmosphere and subjected to electron beamirradiation. Five different amounts of irradiation were used: 30 kGy,100 kGy, 300 kGy, 900 kGy, and only heating to 400° C. (not irradiated).

Abrasion properties were evaluated by the Taber's abrasion resistancetest. The Taber's abrasion resistance test is performed by placingScotch-Brite (registered trademark) (#3000) and a 2-kg weight on theirradiated sample, rotating Scotch-Brite (registered trademark) at 500rpm, measuring a reduction in the thickness of the PFA film due tofriction applied by Scotch-Brite (registered trademark) with respect tothe number of revolutions.

FIG. 1 shows the evaluation results of the abrasion properties. In FIG.1, the horizontal axis of the graph indicates the total number ofrevolutions of Scotch-Brite (registered trademark). The vertical axisindicates the reduction in the thickness of the sample. The resultsdemonstrated as follows: The amount of abrasion was reduced as theamount of irradiation was increased from 30 kGy to 100 kGy compared witha nonirradiated sample and that the abrasion resistance wassignificantly improved. At 300 kGy, the reduction in thickness wasincreased. At 900 kGy, the sample was immediately abraded. At 300 kGyand 900 kGy, the fluorocarbon resin began to degrade, which revealedthat the abrasion resistance was reduced. Thus, in the case where thisfluorocarbon resin is used at the temperature, an amount of irradiationof about 100 kGy is appropriate.

Next, comparisons were made between crosslinked PFA and other materials.As other materials, three super engineering plastics, which are hard andexcellent in abrasiveness, were used. Specifically, polyamide-imide(PAI) (Vylomax HR-16NN, manufactured by Toyobo Co., Ltd.), polyimide(PI) (U-Varnish-S, manufactured by Ube Industries, Ltd.), andpolyetheretherketone (PEEK) (PEEK-COATING, manufactured by OkitsumoIncorporated) were used. FIG. 2 shows the evaluation results. Theresults demonstrated that the crosslinked PFA had abrasion propertiessuperior than those of super engineering plastics, such as PAI, PI, andPEEK.

ii. Test of Adhesion Properties

Next, an experiment to improve the adhesion of a fluorocarbon resin to abase by electron beam irradiation was performed.

A sample was produced as follows: A fluorocarbon resin dispersion (PFAdispersion 950 HP, manufactured by Du Pont-Mitsui Fluorochemicals) wasapplied by dipping onto a 5-mm-thick aluminum plate and polyimide (PI)(U-Varnish-S, manufactured by Ube Industries, Ltd.) and baked at 380°C., thereby forming films each having a thickness of 5 μm. The resultingfilms were subjected to electron beam irradiation with an irradiationunit equipped with a chamber and a hot plate (min-EB, output: 30 kV,manufactured by Ushio Inc.) under a nitrogen atmosphere at a hot-platetemperature of 400° C. and an amount of electron beam irradiation of 100kGy.

The evaluation was made by a detachment test, what is called a cross-cuttest, according to JIS-K-5400 (1998 edition). The cross-cut test is asfollows: Cuts are made in a surface of the sample so as to penetrate tothe plate, thereby forming a grid of 100 squares each measuring about1×1 mm. An operation in which a tape is adhered to the grid and thenremoved is repeated. This test is to determine how many repetitions ofthe operation are necessary to detach the sample. The test resultsdemonstrated that all squares of nonirradiated PFA on the aluminum platewere detached after several repetitions of the operation and that noneof the squares of each of the irradiated PFA films on the aluminum plateand PI was detached even after 100 repetitions of the operation. Thatis, according to the foregoing standard, the evaluation of thedetachment state is based on classes 0 to 10. The samples wereclassified into class 10 (each cut is thin, the edges of the cuts aresmooth, none of the squares of the grid is detached, and no flake isdetached at the intersections of the cuts). Thus, it was found that theirradiation of the fluorocarbon resin with an electron beam at a hightemperature under an oxygen-free atmosphere significantly increasesadhesion to the base.

Next, the evaluation was made by a peeling test, in which a sheetcomposed of a fluorinated ethylene-propylene copolymer (FEP) is bondedto a fluorocarbon film on a base and a force necessary to peel the filmis measured. Table I shows the test results. In all test pieces,although the evaluation was not completed because detachment occurred atthe interface between the FEP sheet and the sample, it was found thateach of the samples had an adhesive strength as high as 1.7 kg/1.5 cm ormore.

Note that in the case where a primer (adhesive) is not used or etchingtreatment (surface treatment of the base) is not performed, the adhesivestrength determined by the peeling test is an unmeasurable level(substantially zero).

TABLE I Amount of Adhesive strength irradiation (kg/1.5 cm) Base (kGy) 12 Average Remarks Aluminum 30 2.24 1.63 1.93 Detachment at interfacebetween fluorocarbon film and FEP sheet Aluminum 100 1.98 1.53 1.76Detachment at interface between fluorocarbon film and FEP sheet Aluminum300 1.76 1.7 1.73 Detachment at interface between fluorocarbon film andFEP sheet Aluminum 900 2.3 2.51 2.41 Detachment at interface betweenfluorocarbon film and FEP sheet Polyimide 100 1.5 0.61 1.05 Detachmentat interface between polyimide and fluorocarbon film

2. First Embodiment

This embodiment is an embodiment according to the first aspect andrelates to cookware.

(Production of Cookware)

FIG. 3 is a conceptual drawing of an inner pot of a rice cooker as anexample of cookware. In FIG. 3, reference numeral 1 denotes a base, andreference numeral 2 denotes a thin film-like fluorocarbon resin on thebase 1.

The base 1 includes a bottom and a side. Examples of a material for thebase 1 that can be used include metals such as stainless steel,aluminum, and aluminum alloys.

The fluorocarbon resin layer 2 is arranged on a horizontal inner wall ofthe bottom and a substantially vertical inner wall of the side, has athickness of 15 μm, and is crosslinked by electron beam irradiation. Thefluorocarbon resin layer 2 is preferably formed of PFA (PFA dispersion950 HP, manufactured by Du Pont-Mitsui Fluorochemicals). The PFA iscomposed of a thermoplastic fluorocarbon resin and has a solid contentof 33% and a particle size of approximately several tenths of amicrometer; hence, the PFA is suitable for the formation of a thin filmusing, for example, a fluorocarbon resin dispersion.

The inner pot having the structure described above is produced inaccordance with a flow chart of a production procedure shown in FIG. 4.

First, a flat-shaped base is prepared. As shown in FIG. 5, theflat-shaped base 1 composed of an aluminum alloy (Al—Mn-based, JIS 3003,3004, or 3005) and having a thickness of about 0.6 to about 3.0 mm isprepared. In an induction heating (IH) cooker, a stainless steel sheet 3is arranged on the back side of the base 1, in some cases, as indicatedby a chain double-dashed line in FIG. 5.

In step S2, a dispersion of a fine powder composed of an uncrosslinkedfluorocarbon resin (PFA) dispersed in water is applied to the uppersurface of the base 1 by spin coating to form the thin fluorocarbonresin layer 2.

In step S3, the base 1 is placed in a temperature-controlled oven andbaked at 380° C. to 420° C. for 10 to 20 minutes. In step S4, electronbeam irradiation is performed in a nitrogen gas atmosphere to crosslinkthe resin while the fluorocarbon resin layer 2 is melted at atemperature equal to or higher than the melting point of the resin. Thatis, as shown in FIG. 6, the base 1 that has the fluorocarbon resin layer2 facing down is transported above an electron beam irradiationapparatus 20 in the direction indicated by an arrow, so that the entirefluorocarbon resin layer 2 is uniformly subjected to electron beamirradiation. To sufficiently crosslink the fluorocarbon resin layer 2,the amount of electron beam irradiation is preferably about 100 kGy. Theirradiation unit (min-EB, manufactured by Ushio Inc.) including10-electron-beam tubes 21 arranged in a staggered configuration is usedas the electron beam irradiation apparatus 20 because it is versatile,inexpensive, and compact.

According to the present invention, the fluorocarbon resin layer has asmall thickness. Thus, a single-layer coating can be formed.Furthermore, electron beams reach the base with the foregoinggeneral-purpose electron beam irradiation apparatus, providing a producthaving the strong adhesion of the fluorocarbon resin layer to the base.

In step S5, the base 1 is subjected to pressing or spinning so as tohave a desired shape.

In this way, the inner pot provided with the crosslinked thinfluorocarbon resin layer 2 formed on the base 1 is completed by theproduction process suitable for mass production. The abrasion resistanceof the fluorocarbon resin layer 2 of the resulting inner pot isevaluated by the Taber's abrasion resistance test. Furthermore, theadhesive strength between the base and the fluorocarbon resin layer isevaluated by the cross-cut test (JIS-K-5400, 1998 edition). In bothcases, whether the results meet predetermined criteria is checked.

A detailed description will be given below on the basis on an example.

Example

In this example, a fluorocarbon resin composite including an aluminumbase was subjected to pressing with a press actually used for producingan inner pot of a rice cooker in order to check whether the fluorocarbonresin composite was able to withstand pressing and whether thefluorocarbon resin composite did not cause a problem.

(1) Production of Fluorocarbon Resin Composite

i. Coating of Fluorocarbon Resin on Base

Two different fluorocarbon resins, i.e., a PTFE dispersion (DI-F,manufactured by Daikin Industries, Ltd.) and a PFA dispersion (945 HP,manufactured by Du Pont-Mitsui Fluorochemicals), were each applied byspin coating to a disk-shaped aluminum (3004) base having a diameter of360 mm and a thickness of 1.2 mm, dried, and baked at 400° C. to formtwo different fluorocarbon resin composites each including a PTFE filmor a PFA film serving as fluorocarbon resin layer having a thickness of10 μm on the aluminum base.

ii. Electron Beam Irradiation

FIG. 7 is a conceptual drawing showing an electron beam irradiationmethod. In FIG. 7, the fluorocarbon resin composite 31 including thefluorocarbon resin layer 2 (PTFE or PFA film) facing up and the aluminumbase 32 facing down was placed on a hot plate 35 arranged in a chamber33 for electron beam irradiation. An opening 36 through which electronbeams passed was arranged above partition walls 34 of the chamber 33. Toseal the chamber 33, the opening 36 was covered with titanium foil 37with a thickness of 30 μm. The temperature of the hot plate 35 was setto 340° C. for the fluorocarbon resin composite including the PTFE film.The temperature of the hot plate 35 was set to 310° C. for thefluorocarbon resin composite including the PFA layer. The gas in thechamber 33 was replaced with nitrogen (an oxygen concentration in thechamber after replacement of 5 ppm). The layers were irradiated withelectron beams at a dose of 60 kGy with a conveyor-type electron beamirradiation system 38 (acceleration voltage: 1.16 MeV, manufactured byNHV Corporation), thereby crosslinking each of PTFE and PFA constitutingthe fluorocarbon resin layers 2.

iii. Pressing

Each of the samples after electron beam irradiation was cold-stampedinto a bowl-shaped article with a die for an inner pot of a rice cooker,thereby forming an inner pot having a depth of 120 mm and a diameter of190 mm. Although the stamping of each sample into the bowl-shapedarticle applied stresses, such as pressure, friction, and tension, tothe aluminum base 32 and the fluorocarbon resin layer 2, the resultingPTFE and PFA films of the inner pots were free from problems, such asdetachment and flaws. The results demonstrated that the PTFE film andthe PFA film in this example were able to withstand pressing withoutperforming surface treatment such as etching of the base.

(2) Performance Evaluation

i. Evaluation of Abrasion Resistance

The abrasion resistance of each of the resulting PTFE film and the PFAfilm of the inner pots was evaluated by the Taber's abrasion resistancetest. FIG. 8 shows the evaluation results in addition to results in thecase where nonirradiated PTFE and PFA films were provided. FIG. 8demonstrated that the irradiation of radiation resulted in a significantincrease in the abrasion resistance of the PTFE and PFA films.Furthermore, in the irradiated PTFE film, surprisingly, the amount ofabrasion was zero even after 20,000 revolutions.

ii. Evaluation of Adhesive Strength

The adhesion strength of each of the resulting PTFE film and the PFAfilm of the inner pots was evaluated by the detachment test, what iscalled the cross-cut test. The evaluation was made even if the filmshaving flaws and pin holes were subjected to pressing. Thus, 100 cutswere made in each of the PTFE film and the PFA film so as to penetrateto a corresponding one of the bases, thereby forming a grid of 100squares. Furthermore, two different projections, called Erichsen, havingthicknesses of 5 mm and 10 mm were formed in the middle of each sample.The evaluation of the samples was made. A peeling operation was repeated100 times. Table II shows the test results.

TABLE II Material of fluorocarbon resin film PTFE PFA Erichsen thickness(mm) 0 100/100 100/100 5 100/100 100/100 10 100/100 100/100 * In TableII, numerators are the numbers of undetached squares, and denominatorsare the numbers of peeling operations.

The results shown in Table II demonstrated that the PTFE film and thePFA film formed in this example were not detached in the test forevaluating the adhesive strength and thus had good adhesive strength.

iii. Performance Evaluation as Cookware

An evaluation test in which actual cooking was simulated was performed.Specifically, as shown in FIG. 9, cuts 39 each in the form of an X weremade in a PTFE film and a PFA film, each of the cuts 39 having a lengthof 100 mm and a width of 50 mm and penetrating to a corresponding one ofthe bases. “Oden No Moto (Soup mix for ODEN)” (registered trademark)manufactured by S & B Foods, Inc. was charged into a rice cooker andboiled for 1000 hours. Then whether the PTFE film and the PFA film weredetached from the bases or not was checked. If the adhesion between thebases and the PTFE and PFA films is insufficient, a soup (Oden soup)will penetrate to interfaces between them during boiling to causedetachment of the PTFE film and the PFA film. In this example, however,it was found that no detachment occurred and thus the composites wereable to be used as cookware without problems.

3. Second Embodiment

This embodiment is an embodiment according to the second aspect andrelates to a roller for use in office automation equipment.

(Production of Roller for Use in Office Automation Equipment)

FIG. 10 is a partially cutout conceptual drawing showing a fixing rollerfor use in office automation equipment according to the presentinvention. In FIG. 10, reference numeral 41 denotes a circular base, andreference numeral 2 denotes a thin film-like fluorocarbon resin layer onthe circular base 41.

The circular base 41 has a cylindrical shape. A heater (not shown) andso forth are accommodated in the cylinder. Examples of a materialconstituting the circular base 41 include heat-resistant resins such aspolyimide resins and polyamide-imide resins and metals such as stainlesssteel and aluminum. The fluorocarbon resin layer 2 has a thickness of 15μm and is crosslinked by electron beam irradiation.

The fixing roller having the structure described above is produced inaccordance with a flow chart of a production procedure shown in FIG. 11.

First, in step S1, the circular base 41 is prepared. For example, thecircular base 41 composed of polyimide is produced by a method describedbelow. That is, polyimide varnish is applied to the outside of adrum-shaped die having a predetermined outer diameter and apredetermined length while the die is being rotated. Then the die isheated to perform imidization, thereby forming the circular base 41around the die, the circular base 41 having a thickness of about 80 μmand being composed of polyimide.

In step S2, an uncrosslinked fluorocarbon resin 2 (PFA) is applied ontothe circular base 41 by a dispersion method or the like to form a thinfilm. As a material of the fluorocarbon resin 2, PFA (950 HP,manufactured by Du Pont-Mitsui Fluorochemicals) is preferably used. ThePFA is composed of a thermoplastic fluorocarbon resin and has a solidcontent of 33% and a particle size of approximately several tenths of amicrometer; hence, the PFA is suitable for the formation of a thin filmby the dispersion method or the like.

In the present invention, an elastic intermediate layer may be formed onthe outer surface of the circular base 41, and the fluorocarbon resin 2may be applied onto the outer surface of the intermediate layer. Forexample, an intermediate layer composed of synthetic rubber such assilicone rubber and having a thickness of about 200 μm is formed on asurface of the circular base 41 with a dispenser. Then the fluorocarbonresin 2 is applied onto the outside of the intermediate layer.

In step S3, the fluorocarbon resin 2 is heated to 380° C. to meltdispersion particles, thereby forming a film of the fluorocarbon resin2. Simultaneously, the fluorocarbon resin 2 is subjected to electronbeam irradiation in a nitrogen gas atmosphere before the temperature ofthe fluorocarbon resin 2 is decreased to a temperature equal to or lowerthan its melting point, thereby crosslinking the fluorocarbon resin 2.Note that the heating temperature is appropriately adjusted in responseto a material constituting the base. To sufficiently crosslink thefluorocarbon resin 2, the amount of electron beam irradiation is set toabout 100 kGy. An irradiation unit (min-EB, manufactured by Ushio Inc.)is used as an electron beam irradiation apparatus because it isversatile, inexpensive, and compact. In the case where electron beamirradiation is not performed, a primer layer is needed to bond thecircular base 41 to the fluorocarbon resin layer 2. In the methodaccording to the present invention, strong bonding can be achieved byelectron beam irradiation without using the primer layer.

In step S4, the fluorocarbon resin 2 is cooled, resulting in the fixingroller. The abrasion resistance of the fluorocarbon resin layer 2 of theresulting fixing roller is evaluated by the Taber's abrasion resistancetest. The adhesive strength between the circular base 41 and thefluorocarbon resin layer 2 is evaluated by the peeling test. In bothcases, whether the results meet predetermined criteria is checked. Anexample of another method for evaluating abrasion resistance is a linearreciprocating wear test (test temperature: 250° C.).

4. Third Embodiment

This embodiment is an embodiment according to the second aspect andrelates to a roller for use in office automation equipment.

(Production of Roller for Use in Office Automation Equipment)

FIG. 12 is a flow chart illustrating another procedure for making afixing roller.

In step S1, an uncrosslinked fluorocarbon resin (PFA) tube is producedwith an upright extruder shown in FIG. 13. In FIG. 13, reference numeral2 denotes a fluorocarbon resin (PFA) tube, reference numeral 51 denotesa die (outlet) of the extruder, and reference numeral 53 denotes anelectron beam irradiation apparatus 53. The die 51 is surrounded by anitrogen gas atmosphere.

A molten uncrosslinked fluorocarbon resin (PFA) obtained by heatingfluorocarbon resin pellets (PFA, 950 HP) to a temperature equal to orhigher than its melting point is fed into the die 51 of the uprightextruder. A ring-shaped opening 52 is arranged at the lower end of thedie 51. The molten uncrosslinked fluorocarbon resin is extruded from theopening 52 in a downward direction to form the uncrosslinkedfluorocarbon resin tube 2.

In step S2, the downwardly extruded fluorocarbon resin tube 2 issubjected to electron beam irradiation in a nitrogen gas atmosphere withthe electron beam irradiation apparatus 53 arranged in a circularpattern and below the extruder before the temperature is decreased to atemperature equal to or lower than its melting point, therebycrosslinking the resin. The foregoing irradiation unit (min-EB,manufactured by Ushio Inc.) is used as the electron beam irradiationapparatus 53. To sufficiently crosslink the fluorocarbon resin tube 2,the amount of electron beam irradiation is preferably about 100 kGy. Thecrosslinked fluorocarbon resin tube 2 is cut into a predeterminedlength.

In step S3, the circular base 41 is produced. For example, polyimidevarnish is applied to the outside of a drum-shaped die having apredetermined outer diameter and a predetermined length while the die isbeing rotated. Then the die is heated to perform imidization, therebyforming the circular base 41 having a thickness of about 80 μm and beingcomposed of polyimide.

In step S4, the outer surface of the circular base 41 is covered withthe fluorocarbon resin tube 2 serving as the fluorocarbon resin layer 2.An example of a covering method is a method including applying a viscousadhesive to the outer peripheral surface of the circular base 41 andthen forcedly sliding the fluorocarbon resin tube 2 over the circularbase. Another example thereof is a method using a heat-shrinkablefluorocarbon resin tube as the fluorocarbon resin tube 2, the methodincluding inserting the circular base 41 into the fluorocarbon resintube 2 and then allowing the fluorocarbon resin tube 2 to shrink byheating the fluorocarbon resin tube 2, thereby bonding the outerperipheral surface of the circular base 41 to the inner peripheralsurface of the fluorocarbon resin tube 2.

In this way, the fixing roller including the thin fluorocarbon resinlayer 2 on the circular base 41 is completed by extrusion suitable formass production.

5. Fourth Embodiment

This embodiment is an embodiment according to the second aspect andrelates to a roller for use in office automation equipment.

(Production of Roller for Use in Office Automation Equipment)

FIG. 14 is a conceptual partially cross-sectional view illustrating amethod for producing a fixing roller by another extrusion. In FIG. 14,reference numeral 41 denotes the circular base, reference numeral 61denotes a die (outlet) of an extruder, and reference numeral 53 denotesthe electron beam irradiation apparatus 53. The die 61 of the extruderhas a hole 63 with a diameter slightly larger than that of the circularbase 41. As described below, the circular base 41 passes through thehole 63. An opening 62 of the die 61 arranged in a circular pattern islocated in the inner peripheral wall of the hole 63. The moltenuncrosslinked fluorocarbon resin (PFA) 2 that is heated to its meltingpoint or higher is fed into the die 61. The die 61 is surrounded by anitrogen gas atmosphere.

The electron beam irradiation apparatus 53 is arranged in a circularpattern and behind the extruder. The foregoing irradiation unit (min-EB,manufactured by Ushio Inc.) is used as the electron beam irradiationapparatus 53.

When the circular base 41 transported from the direction indicated by anarrow passes through the hole 63 of the extruder, the moltenuncrosslinked fluorocarbon resin (PFA) 2 heated to its melting point orhigher is extruded from the opening 62 of the die 61 so as to beuniformly applied to the outer peripheral surface of the circular base41.

The circular base 41 provided with the fluorocarbon resin 2 on its outerperipheral surface is further transported. The fluorocarbon resin 2 issubjected to electron beam irradiation with the electron beamirradiation apparatus 53 in a nitrogen gas atmosphere at a positionwhere the electron beam irradiation apparatus 53 is arranged before thetemperature of the fluorocarbon resin 2 is decreased to a temperatureequal to or lower than its melting point, thereby crosslinking thefluorocarbon resin 2. To sufficiently crosslink the fluorocarbon resin2, the amount of electron beam irradiation is preferably about 100 kGy.

Hereafter, the fluorocarbon resin 2 is cooled, resulting in the fixingroller. In this way, the thin fluorocarbon resin layer 2 is formed onthe circular base 41 by extrusion suitable for mass production.

6. Fifth Embodiment

This embodiment is an embodiment according to the second aspect andrelates to a belt for use in office automation equipment.

(Production of Belt for Use in Office Automation Equipment)

FIG. 15 is a partially cutout conceptual drawing showing a transfer belt(or transfer fixing belt) for use in office automation equipmentaccording to the present invention. In FIG. 15, reference numeral 71denotes a circular base 71, and reference numeral 2 denotes a thinfilm-like fluorocarbon resin layer on the circular base 71.

The circular base 71 has a strip-like shape. In the case of using thecircular base 71 as a belt, a heater and so forth are accommodated inthe inside. Examples of a material constituting the circular base 71include heat-resistant resins such as polyimide resins andpolyamide-imide resins and metals such as stainless steel and aluminum.

The fluorocarbon resin layer 2 has a thickness of 10 μm and iscrosslinked by electron beam irradiation. As a material of thefluorocarbon resin layer 2, PFA (950 HP, manufactured by Du Pont-MitsuiFluorochemicals) is preferably used. The PFA is composed of athermoplastic fluorocarbon resin and has a solid content of 33% and aparticle size of about 0.2 μm; hence, the PFA is suitable for theformation of a thin film by the dispersion method or the like.

7. Sixth Embodiment

This embodiment is an embodiment according to the second aspect andrelates to a belt for use in office automation equipment.

(Production of Belt for Use in Office Automation Equipment)

The transfer belt (or transfer fixing belt) shown in FIG. 15 is producedby, for example, in accordance with a flow chart of a productionprocedure shown in FIG. 16. In step S1, the circular base 71 isproduced. For example, the circular base 71 composed of polyimide isproduced by a method described below. That is, polyimide varnish isapplied, and then a die is heated to perform imidization, therebyforming the circular base 71 around the die, the circular base 71 havinga thickness of about 80 μm and being composed of polyimide. In thepresent invention, an elastic intermediate layer may be formed on theouter surface of the circular base 71, and the fluorocarbon resin 2 maybe applied onto the outer surface of the intermediate layer. Forexample, an intermediate layer composed of synthetic rubber such assilicone rubber and having a thickness of about 200 μm is formed on asurface of the circular base 71 with a dispenser.

In step S2, an uncrosslinked fluorocarbon resin (PFA) dispersion isapplied to form a thin film composed of the fluorocarbon resin on thecircular base 71.

In step S3, the powdery fluorocarbon resin is melted by heating (heatingtemperature: 380° C.) to form a uniform thin film. Simultaneously, thefluorocarbon resin is subjected to electron beam irradiation in anitrogen gas atmosphere before the temperature of the fluorocarbon resinis decreased to a temperature equal to or lower than its melting point,thereby crosslinking the fluorocarbon resin. To sufficiently crosslinkthe fluorocarbon resin, the amount of electron beam irradiation is setto about 100 kGy. An irradiation unit (min-EB, manufactured by UshioInc.) is used as an electron beam irradiation apparatus because it isversatile, inexpensive, and compact.

In step S4, the fluorocarbon resin is cooled. At this time, if thefluorocarbon resin is rapidly cooled, the crystallization of thefluorocarbon resin does not easily occur, thus improving the flexresistance of the fluorocarbon resin layer 2. Furthermore, the use of aside-chain-type fluorocarbon resin suppresses crystallization and isthus preferred. Moreover, the use of a fluorocarbon resin having ahigher molecular weight improves flex resistance and is thus preferred.Note that each of the circular base, the silicone rubber, and thefluorocarbon resin is adjusted by carbon conduction or ionic conductionso as to have a volume resistivity of about 10¹¹ Ω·cm. Thereby, thetransfer fixing belt is completed. The abrasion resistance of thefluorocarbon resin layer 2 of the resulting transfer belt is evaluatedby the Taber's abrasion resistance test. The adhesive strength betweenthe circular base 71 and the fluorocarbon resin layer 2 is evaluated bythe cross-cut test (JIS-K-5400, 1998 edition). In both cases, whetherthe results meet predetermined criteria is checked. As another methodfor evaluating abrasion resistance, the foregoing linear reciprocatingwear test (test temperature: 250° C.) may be available.

8. Seventh Embodiment

This embodiment is an embodiment according to the second aspect andrelates to a belt for use in office automation equipment.

The transfer belt shown in FIG. 15 is also produced in accordance with aflow chart of a production procedure shown in FIG. 17. In step S1, adispersion of a fine powder composed of an uncrosslinked fluorocarbonresin (PFA) dispersed in water is applied to a ring-shapedstainless-steel die (cylinder) having a mirror-polished inner peripheralsurface by dipping and baked at 380° C., thereby forming a thin film(with a thickness of about 10 μm) of the uncrosslinked fluorocarbonresin on the inner peripheral surface of the ring-shaped die.

In step S2, an intermediate layer is formed. For example, thering-shaped die provided with the fluorocarbon resin layer on its innerperipheral surface is placed in a plasma processing chamber. A counterelectrode is arranged inside the ring-shaped die so as to face thering-shaped die. The plasma processing chamber is filled with a Heatmosphere. A high-frequency power having predetermined output, voltage,and frequency is applied to the counter electrode and the ring-shapeddie also functioning as an electrode for plasma generation. Thisgenerates a plasma in a gap between the ring-shaped die and the counterelectrode, so that the inner peripheral surface of the fluorocarbonresin layer is subjected to plasma treatment.

After the treatment such as plasma treatment of the inner peripheralsurface of the fluorocarbon resin layer, primers 101A and 101B(manufactured by Shin-Etsu Chemical Co.) are mixed in a ratio of 1:1.The resulting mixture is applied to the inner peripheral surface of thefluorocarbon resin and dried to form an adhesive film having a thicknessof about 5 μm. Then silicone rubbers KE-1370A and KE-1370B (manufacturedby Shin-Etsu Chemical Co.) are mixed in a ratio of 1:1. The viscosity ofthe mixture is adjusted using a solvent. The mixture is applied to theadhesive film and cured at 150° C., thereby forming the intermediatelayer having a thickness of about 200 μm.

In step S3, a circular base is formed. For example, the inner peripheralsurface of the intermediate layer is subjected to plasma treatment inthe same way as the plasma treatment of the fluorocarbon resin layer. Athermoplastic polyimide (Rikacoat PN-20, manufactured by New JapanChemical Co., Ltd.) is applied and dried at 220° C., thereby forming thecircular base 71 having a thickness of about 80 μm. Then the circularbase, the intermediate layer, and the fluorocarbon resin layer arepulled out from the die, thereby affording a circular belt including thecircular base 71, the intermediate layer 72, and the fluorocarbon resinlayer 2 (surface layer) shown in FIGS. 18(A) and 18(B). Note that eachof the surface layer (fluorocarbon resin layer), the adhesive layer(primer layer), the elastic layer (silicone rubber layer), and the base(polyimide layer) is adjusted by carbon conduction or ionic conductionso as to have a volume resistivity of about 10¹¹ Ω·cm.

In step S4, after a core is inserted into a hollow portion of thecircular belt, the circular belt is rotated as shown in FIG. 18.Nitrogen gas heated to 400° C. is blown on the surface layer of thecircular belt, increasing the temperature of the fluorocarbon resinlayer 2 to a temperature equal to or higher than its melting point. ThenElectron beam irradiation is performed, resulting in the crosslinkedfluorocarbon resin layer 2. That is, the entire fluorocarbon resin layer2 is uniformly subjected to electron beam irradiation while the circularbelt provided with the fluorocarbon resin layer 2, which is a targetirradiated, on its outer peripheral surface is being rotated and whilethe electron beam irradiation apparatus 53 arranged outside the circularbelt is being translated in the x direction indicated by an arrow (thatis, spiral irradiation). To sufficiently crosslink the fluorocarbonresin layer 2, the amount of electron beam irradiation is preferablyabout 100 kGy. The foregoing irradiation unit (min-EB, manufactured byUshio Inc.) is used as the electron beam irradiation apparatus 53. Acooling point is set at a position located 180 degrees apart from aheating point. Rapid cooling is performed so as not to degrade theintermediate layer 72 before the temperature of the intermediate layer72 located under the fluorocarbon resin layer 2 reaches thedecomposition temperature. Rapid cooling also improves the flexresistance of the fluorocarbon resin layer 2.

In this way, the transfer belt including the circular base 71, theintermediate layer 72, and the fluorocarbon resin layer 2 is completedby the production process suitable for mass production.

1-9. (canceled)
 10. A method for producing a fluorocarbon resincomposite comprising the steps of applying an uncrosslinked fluorocarbonresin onto a base; heating the fluorocarbon resin to a temperature equalto or higher than the melting point of the fluorocarbon resin;subjecting the fluorocarbon resin to electron beam irradiation in alow-oxygen atmosphere to crosslink the fluorocarbon resin; and machiningthe base in such a manner that the base has a desired shape. 11-21.(canceled)